The advent of wide band-gap semiconductors in power electronics has led to the scope of efficient power conversion being pushed further than ever before. This development has allowed for systems to operate at higher and higher voltages than previously achieved. One area of consideration during this high voltage transition is the synchronous rectifier, which is traditionally designed as an afterthought. Prior research in synchronous rectifiers have been limited to low voltage, high current converters. There is practically no research in high voltage synchronous rectification. Therefore, this dissertation focuses on discovering the unknown nuances behind high voltage synchronous rectifier design, and ultimately developing a practical, scalable solution. There are three main issues that must be addressed when designing a high voltage synchronous rectifier: (1) high voltage sensing; (2) light load effects; (3) accuracy. The first hurdle to designing a high voltage SR system is the high voltage itself. Traditional methods of synchronous rectification (SR) attempt to directly sense voltage or current, which is not possible with high voltage. Therefore, a solution must be designed to limit the voltage seen by the sensing mechanism without sacrificing accuracy. In this dissertation, a novel blocking solution is proposed, analyzed, and tested to over 1-kV. The solution is practical enough to be implemented on practically any commercial drain-source SR controller. The second hurdle is the light load effect of the SR system on the converter. A large amount of high voltage systems utilize a LLC-based DC transformers (DCX) to provide an efficient means of energy conversion. The LLC-DCX's attractive attributes of soft-switching and high efficiency allure many architects to combine it with an SR system. However, direct implementation of SR on a LLC-DCX will result in a variety of light load oscillation issues, since the rectifier circuitry can excite the resonant tank through a false load transient phenomena. A universal limiting solution is proposed and analyzed, and is validated with a commercial SR controller. The final hurdle is in optimizing the SR system itself. There is an inherent flaw with drain-source sensing, namely parasitic inductance in the drain-source sense loop. This parasitic inductance causes an error in the sensed voltage, resulting in early SR turn-off and increased losses through the parallel diode. The parasitic will always be present in the circuit, and current solutions are too complex to be implemented. Two solutions are proposed depending on the rectifier architecture: (1) multilevel gate driving for single switch rectifiers; (2) sequential parallel switching for parallel switch rectifiers. In summary, this dissertation focuses on developing a practical and reliable high voltage SR solution for LLC-DCX converters. Three main issues are addressed: (1) high voltage sensing; (2) light load effects; (3) accuracy. Novel solutions are proposed for all three issues, and validated with commercial controllers. / Doctor of Philosophy / High voltage power electronics are becoming increasing popular in the electronics industry with the help of wide band-gap semiconductors. While high voltage power electronics research is prevalent, a key component of high voltage power converters, the synchronous rectifier, remains unexplored. Conventional synchronous rectifiers are implemented on high current circuits where diode losses are high. However, high voltage power electronics operate at much lower current levels, necessitating changes in current synchronous rectifier methods. This research aims to identify and tackle issues that will be faced by both systems and IC designers when attempting to implement high voltage synchronous rectifiers on LLC-DCXs. While development takes planes on a LLC-DCX, the research is applicable to most resonant converters and applications utilizing drain-source synchronous rectifier technology. This dissertation focuses primarily on three areas of synchronous rectifier developments: (1) high voltage compatibility; (2) light load effects; (3) accuracy. The first issue opens the gate to high voltage synchronous rectifier research, by allowing high voltage sensing. The second issue explores issues that high voltage synchronous rectifiers can inadvertently influence on the LLC-DCX itself - a light load oscillation issue. The third issue explores novel methods of improving the sensing accuracy to further reduce losses for a single and parallel switch rectifier. In each of these areas, the underlying problem is root-caused, analyzed, and a solution proposed. The overarching goal of this dissertation is to develop a practical, low-cost, universal synchronous rectifier system that can be scaled for commercial use.

This thesis presents a research project in the field of oxygen system fire safety relating to the heterogeneous burning of iron in normal gravity and reduced gravity. Fires involving metallic components in oxygen systems often occur, with devastating and costly results, motivating continued research to improve the safety of these devices through a better understanding of the burning phenomena. Metallic materials typically burn in the liquid phase, referred to as heterogeneous burning. A review of the literature indicates that there is a need to improve the overall understanding of heterogeneous burning and better understand the factors that influence metal flammability in normal gravity and reduced gravity. Melting rates for metals burning in reduced gravity have been shown to be higher than those observed under similar conditions in normal gravity, indicating that there is a need for further insight into heterogeneous burning, especially in regard to the rate-limiting mechanism. The objective of the current research is to determine the cause of the higher melting rates observed for metals burning in reduced gravity to (a) identify the rate-limiting mechanism during heterogeneous burning and thus contribute to an improved fundamental understanding of the system, and (b) contribute to improved oxygen system fire safety for both ground-based and space-based applications. In support of the work, a 2-s duration ground-based drop tower reduced-gravity facility was commissioned and a reduced-gravity metals combustion test system was designed, constructed, commissioned and utilised. These experimental systems were used to conduct tests involving burning 3.2-mm diameter cylindrical iron rods in high-pressure oxygen in normal gravity and reduced gravity. Experimental results demonstrate that at the onset of reduced gravity, the burning liquid droplet rapidly attains a spherical shape and engulfs the solid rod, and that this is associated with a rapid increase in the observed melting rate. This link between the geometry of the solid/liquid interface and melting rate during heterogeneous burning is of particular interest in the current research. Heat transfer analysis was performed and shows that a proportional relationship exists between the surface area of the solid/liquid interface and the observed melting rate. This is confirmed through detailed microanalysis of quenched samples that shows excellent agreement between the proportional change in interfacial surface area and the observed melting rate. Thus, it is concluded that the increased melting rates observed for metals burning in reduced gravity are due to altered interfacial geometry, which increases the contact area for heat transfer between the liquid and solid phases. This leads to the conclusion that heat transfer across the solid/liquid interface is the rate-limiting mechanism for melting and burning, limited by the interfacial surface area. This is a fundamental result that applies in normal gravity and reduced gravity and clarifies that oxygen availability, as postulated in the literature, is not rate limiting. It is also established that, except for geometric changes at the solid/liquid interface, the heterogeneous burning phenomenon is the same at each gravity level. A conceptual framework for understanding and discussing the many factors that influence heterogeneous burning is proposed, which is relevant to the study of burning metals and to oxygen system fire safety in both normal-gravity and reduced-gravity applications.

<p dir="ltr">To decrease the use of fossil fuels that generate greenhouse gases, there has been a push to find alternative processes for electricity generation. An attractive renewable alternative is to use solar-thermal energy for grid level electricity production. One method used to generate electricity from the conversion of solar-thermal energy is concentrated solar power (CSP) via the power tower paradigm, which involves an array of mirrors that concentrate sunlight to a spot on a tower. The light heats up a heat transfer fluid which later transfers the thermal energy to a working fluid that expands so as to spin a turbine to generate electricity. Current CSP plants have a peak operation temperature of 550℃, but improvements to the heat exchanger are integral to increasing the peak operation temperature of such plants to a 750℃ target. Ceramic/metal composites (cermets) have been proposed for use as heat exchangers in these CSP plants due to the creep resistance of the ceramic component and toughness of the metal component. One potential material that has an attractive combination of properties for this application is the alumina/chromium (Al2O3/Cr) cermet, given the rigidity and creep resistance of the Al2O3 component and the high-temperature toughness of the Cr phase. Compared to other oxidation-resistant oxide/metal cermets, the Al2O3 and Cr components of this cermet have a relatively close average linear thermal expansion match from 25℃ to 750℃, which is advantageous due to the thermal gradients and thermal cycling of the heat exchanger during operation.</p><p dir="ltr">In this dissertation, the Al2O3/Cr cermet was produced via reaction forming (RF) or reactive melt infiltration (RMI). The RF method involves the reaction of Cr2O3 and Al constituent powder mixtures at high temperature and modest pressures to obtain dense Al2O3/Cr plates. The RMI method involves immersing a shaped porous Cr2O3 preform into an Al or Al-Cr alloy bath to infiltrate and react to form Al2O3/Al-Cr plates. For both methods, the plate microstructure was analyzed for the various reaction conditions. The adiabatic temperature increase for the reaction between Cr2O3 and Al liquid or Al-Cr liquid alloys was calculated. Thermal properties (linear coefficient of thermal expansion, heat capacity, thermal diffusivity, thermal conductivity) and mechanical properties for the RF Al2O3/Cr plates were also measured. Lastly, the reaction kinetics between dense, polycrystalline Cr2O3 and a liquid Al-35at% Cr alloy were experimentally determined at various temperatures and compared to models based on different rate-limiting steps.</p>